Heated respiratory hose wiring

ABSTRACT

Helically winding an extruded web to form a wall of a heated hose about a central axis, extruding a bead of plastics material around a heating wire such that the extruded bead comprises the heating wire at a first location within a cross-section of the extruded bead, helically winding the extruded bead onto the wall of the hose to provide a support helix, and exerting tension on the heating wire to draw down the heating wire toward the central axis such that the heating wire migrates radially inward from the first location to a second location within the cross-section of the extruded bead.

REFERENCE TO PROVISIONAL APPLICATION

This Utility Patent Application claims the benefit of the filing date ofProvisional Application Ser. No. 62/499,623 filed Jan. 30, 2017 byMartin E. Forrester, and entitled HEATED RESPIRATORY HOSE ASSEMBLY, thedisclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

The present invention relates to the field of hoses to conveyrespiratory gases to and from patients as part of treating variousmedical conditions, such as traumatic lung injury, sleep apnea, asthma,chronic obstructive pulmonary disease (COPD), hypoxemia and hypotension.Such hoses may be incorporated into assemblies of used to conveyrespiratory gases between a medical device, such as a ventilator orcontinuous positive airway pressure (CPAP) device, and a face mask, anendotracheal tube or tracheostomy stoma of a patient. Such equipment maybe used in a hospital or other medical facility, or may be used at apatient's home, such as at a patient's bedside while sleeping.

It is usually deemed desirable for such gases conveyed to a patientinclude some degree of water vapor to avoid drying tissues of apatient's respiratory system. Also, the respiratory gases that a patientbreathes out also typically include some amount of water vapor. An issuearising from the water vapor in the respiratory gases conveyed both toand from a patient is that of condensation within the hoses. If thetemperature of the gases in one of the hoses falls below the dew pointof the gases within that hose, then water vapor condenses within thathose, and possibly leads to pooling of liquid water within the lowestportion of the hose. As a result, the flow of gases through that hosemay be constricted or even cut off entirely in a manner very much akinto the pooling of water within a sink drain trap. Alternatively oradditionally, depending on where such pooling occurs within a hose, itis possible for a patient to be caused to breathe in pooled water fromwithin a hose and/or for pooled water within a hose to be sent into themedical device. Such developments may be acutely and immediately harmfulto the patient such that the patient may be caused to actually drownfrom inhalation of liquid water into the lungs, and/or the medicaldevice may be damaged by the intake of liquid water, instead of gasesbreathed out by the patient.

Among prior art efforts to address such issues is the addition of watertraps to each such hose. A water trap serves, in essence, as adesignated location along the length of a hose where liquid water can beallowed to pool relatively harmlessly out of the path of flow of gasesthrough the hose to at least minimize any possible obstruction to thepassage of gases through the hose. Unfortunately, the use of water trapssuffers various drawbacks. For a water trap to work effectively, it mustbe positioned at a point along its respective hose that is lowest inelevation such that any liquid water that is caused to condense from therespiratory gases is caused by the force of gravity to proceed towardthe water trap, instead of pooling elsewhere within the hose. Thisrequires some deliberate effort on the part of those who use such hosesand caregivers who prepare such hoses for use to ensure that the mannerin which such hoses are installed and used does indeed result in thewater traps being at the point of lowest elevation along the hoses.However, even if this is successful, each of the water traps holds afinite volume of liquid, and is therefore required to be opened andemptied on a regular basis to prevent overfilling. Also of concern isthe possibility of the liquid within a water trap collecting and growingpathogens that may then propagate into the respiratory gases passingthrough the hoses, and thereby potentially infect the patient.

Another prior art effort to address such issues is to lay heating wiresinside each of such hoses to raise the temperature of the gases thereinto be higher than the dew point, thereby avoiding the occurrence ofcondensation altogether. Unfortunately, it has been found that simplylaying heating wires within a hose results in uneven heating of thegases therein, thereby possibly leaving portions of the hose with atemperature that is still low enough relative to the dew point of thegases therein to allow condensation to occur.

Other issues exist in prior art heated respiratory hose assembliesbeyond that of condensation. The heating of such assemblies oftenentails the use of a temperature sensor that must be inserted at thecorrect location among the circulatory flow of gases to and from thepatient to be effective. Also, many medical devices also employ a gasflow sensor to provide continual confirmation of there being a flow ofrespiratory gases from the medical device to the patient, and thissensor must also be positioned at the correct location among thecirculatory flow of gases to and from the patient to be effective.Unfortunately, many prior art heated respiratory hose assemblies usenumerous individual fittings to connect the lengths of hose together toform the assembly, and to connect the assembly to both the medicaldevice and the face mask, endotracheal tube or tracheostomy stoma at thepatient end of the assembly. These numerous fittings often includeseparate fittings for the locations of the flow and temperature sensors,thereby providing opportunities for errors to occur in the connectionand placement of these sensors.

SUMMARY

The present invention addresses such needs and deficiencies as areexplained above by providing a heated respiratory hose assembly thatincludes a pair of heated hoses and various fittings to conveyrespiratory gases in a closed circuit between a medical device, such asa ventilator or CPAP device, and a patient. Such a hose assembly may beused in a medical environment, such as a hospital, outpatient carefacility or other medical facility, or a non-medical environment, suchas a patient's home or workplace. Such a hose assembly may incorporate arelatively minimal set of components to reduce opportunities for errorsin assembling those components, as well as connecting various sensorsthereto, as part of preparing the hose assembly for use.

Each hose of the heated respiratory hose assembly may incorporateheating wires into its support helix to enable even distribution of theheat generated by the heating wires within the interior of the hose. Theheating wires may be positioned within the support helix at a locationcloser to the interior of the hose and in a manner that uses much of thematerial of the support helix as an insulator against the environmentexternal to the hose to cause a greater proportion of the heat generatedby the heating wires to radiated into the interior of the hose, ratherthan wastefully radiated into the environment external to the hose. Toachieve such placement, a bead of plastics material that forms thesupport helix may be extruded around the heating wires as the heatingwires are fed through the extruder that extrudes the bead of plasticsmaterial during formation of the hose. Additionally, tension may beexerted on the heating wires during formation of the hose to cause theheating wires to be drawn through plastics material of the bead, whilestill molten, and closer to the interior of the hose.

Each hose of the heated respiratory hose assembly may incorporate a pairof hose fittings, one at each end of each hose. Each such hose fittingmay be formed of rigid plastics material and may be shaped and sized toenable connection of its corresponding end of a hose to a medical deviceor to a face mask, endotracheal tube, tracheostomy stoma or othercomponent worn by or otherwise carried by a patient, and may do sodirectly or through at least one other component interposedtherebetween. Each such hose fitting may be permanently coupled to itscorresponding end of a hose by an undermold coupling formed of flexibleplastics material to provide a gas-tight seal between the fitting andits corresponding end of the hose, and/or to provide a strain relief toprevent damage to the hose where the end of the hose is coupled to itscorresponding fitting.

Each undermold coupling may be formed as a single piece of the flexibleplastics material, and may include a generally cylindrical tubularportion and at least one ladder-like grating. Threads may be formed onthe interior surface of the cylindrical tubular portion to enable thecylindrical tubular portion to be threaded onto the exterior of an endof a hose as part of coupling the undermold coupling to an end of ahose. Each hose fitting may be formed as a single piece of the rigidplastics material, and may include a generally cylindrical tubularportion. The cylindrical tubular portion may have a slightly largerdiameter than the cylindrical tubular portion of its correspondingundermold coupling to receive and closely surround the cylindricaltubular portion of its corresponding undermold coupling therein.

A set of slots may be formed through a portion of the cylindrical wallof the cylindrical tubular portion of each hose fitting to interact withthe at least one ladder-like grating of the corresponding undermoldcoupling as part of forming a permanent mechanical coupling between thefitting and the corresponding undermold coupling. As the cylindricaltubular portion of an undermold coupling is received within thecylindrical tubular portion of a hose fitting, a ladder-like grating ofthe undermold coupling may be hinged or may be otherwise partly pulledaway from contact with the exterior of the cylindrical tubular portionof the undermold coupling to allow portions of the ladder-like gratingto be positioned to overlie, and then extend into and through the slotsformed through the cylindrical wall of the cylindrical tubular portionof the hose fitting. In so extending through the slots, those portionsof the ladder-like grating are allowed to come back into contact withthe exterior of the cylindrical tubular portion of the undermoldcoupling. Such an assembled combination of a hose fitting and acorresponding undermold coupling may then be heated to cause bonding ofthe flexible plastics material of the undermold coupling to the rigidplastics material of the hose fitting to form a gas-tight sealtherebetween, and to cause bonding between the portions of theladder-like grating that extend through the slots and the exteriorsurface of the cylindrical tubular portion of the undermold to aid inpermanently mechanically interlocking the hose fitting to the undermold.

At one end of each hose, the support helix may be partially unwound, andthe unwound end of the support helix may be extended at least partiallywithin the corresponding hose fitting to an electrical connector throughwhich the heating wires within the support helix may receive electricalpower. At the electrical connector, the ends of the heating wires at theunwound end of the support helix may each be directly soldered to, orotherwise directly electrically connected to, an electrical contact ofthe electrical connector to. In embodiments in which the hose fitting isa Y-fitting, a T-fitting, or some other form of three-way fitting, suchan electrical connector may be carried within a plug that may be carriedwithin, and may entirely close, one of the three cylindrical connectionsof the hose fitting. In this way, one of the three cylindricalconnections of the hose fitting through which gases may have otherwisebeen caused to flow may be repurposed to serve as an electricalconnection point.

In other embodiments, the electrical connector may be located entirelyoutside of the hose fitting. In such embodiments, the unwound end of thesupport helix may be caused to further extend out of the hose fittingand to the location of the electrical connector in the environmentexternal to the hose fitting and external to the corresponding hose. Theportion of the unwound end of the support helix that extends out of thehose fitting may be sheathed in heat-shrink tubing or other material toprovide a degree of physical protection to that portion of the unwoundend of the support helix. Such heat-shrink tubing or other materialproviding such a sheath may also provide thermal insulation to prevent apatient or other person who comes into contact with that portion of theunwound end of the support helix being burned by the heat emitted by theheating wires extending therethrough. In this way, the portion of theunwound end of the support helix that extends outside of the hosefitting is repurposed to serve as a “pigtail” to enable an electricalconnection to a medical device to provide electric power to the heatingwires within the support helix.

BRIEF DESCRIPTION OF THE DRAWINGS

A fuller understanding of what is disclosed in the present applicationmay be had by referring to the description and claims that follow, takenin conjunction with the accompanying drawings, wherein:

FIG. 1A is an elevational view of an example embodiment of a heatedrespiratory hose assembly.

FIG. 1B is a perspective view of the heated respiratory hose assembly ofFIG. 1A showing details of electrical connectors thereof.

FIG. 1C is another perspective view of the heated respiratory hoseassembly of FIG. 1A.

FIG. 1D is an exploded perspective view of the heated respiratory hoseassembly of FIG. 1A showing details of the electrical connectors thereofand details of the coupling of hoses to hose fittings thereof.

FIG. 1E is another exploded perspective view of the heated hose assemblyof FIG. 1A.

FIG. 2A is a block diagram of heated respiratory hose assembly of FIG.1A showing details of the flow of respiratory gases therethrough and themonitoring of flow and temperature thereof.

FIG. 2B is a perspective view of the inspiratory hose assembly of theheated respiratory hose assembly of FIG. 1A showing details of a sensorharness that is to be connected thereto.

FIG. 2C is a perspective view of the inspiratory inlet fitting of theinspiratory hose assembly of FIG. 2B showing features of the inspiratoryinlet fitting to aid in correctly connecting a flow sensor of the sensorharness to enable correct operation thereof.

FIG. 3A is an exploded perspective view of an alternate embodiment of aheated respiratory hose assembly.

FIG. 3B is a perspective view of another alternate embodiment of aheated respiratory hose assembly.

FIG. 3C is a perspective view of the inspiratory hose assembly of stillanother embodiment of a heated respiratory hose assembly.

FIG. 4A is a cross-sectional view of a portion of one of the hoses ofany of the embodiments of heated respiratory hose assembly of any ofFIG. 1A, 3A, 3B or 3C showing details of the wall and support helixthereof.

FIG. 4B is a combination of perspective and cross-sectional views of aportion of the support helix of the hose of FIG. 4A showing details ofthe heating wires incorporated therein.

FIG. 4C is a perspective view of components of a hose making apparatusthat may be adapted to make the hose of FIG. 4A.

FIG. 4D is a block diagram of components of a hose making apparatus thathas been adapted to make the hose of FIG. 4A.

FIG. 4E is a cross-sectional view of a portion of the hose of FIG. 4Aduring the making thereof, and showing details of combining the supporthelix and wall thereof.

FIG. 4F is another cross-sectional view of the portion of the hose shownin FIG. 4E during the making thereof, and showing details of the bondingof the support helix to the wall thereof and of the drawing of theheating wires thereof toward the interior of the hose.

FIG. 5A is a perspective view a hose fitting and corresponding undermoldcoupling of any of the embodiments of heated respiratory hose assemblyof any of FIG. 1A, 3A, 3B or 3C showing details of the features of oneof the hose fittings and corresponding undermold coupling that are usedto couple each to the other, and that are used to couple the undermoldcoupling to an end of one of the hoses.

FIG. 5B is another perspective view of the hose fitting andcorresponding undermold coupling of FIG. 5A showing details of themanner in which features of each are used to coupled each to the other.

FIG. 5C is an elevational view of the hose fitting and correspondingundermold coupling of FIG. 5A prior to the coupling of each to theother.

FIG. 5D is a cross-sectional view of the hose fitting and correspondingundermold coupling of FIG. 5A during the coupling of one to the other.

FIG. 5E is another cross-sectional view, similar to FIG. 5D, of the hosefitting and corresponding undermold coupling of FIG. 5A during thecoupling of one to the other.

FIG. 6A is a partial perspective view of the inspiratory hose assemblyof the heated respiratory hose assembly of FIG. 1A showing details ofthe electrical connection of an unwound end of the support helix of thehose thereof to an electrical connector carried within a plug within ahose fitting thereof.

FIG. 6B is another partial perspective view of the inspiratory hoseassembly of FIG. 6A showing further details of the electrical connectionof the unwound end of the support helix to the electrical connector.

FIG. 6C is a partial perspective view of the expiratory hose assembly ofthe heated respiratory hose assembly of FIG. 1A showing details of theelectrical connection of an unwound end of the support helix of the hosethereof to an electrical connector carried within a plug within a hosefitting thereof.

FIG. 6D is an exploded perspective view of the combination of the plugand electrical connector of the inspiratory hose assembly of FIGS. 6Aand 6B showing details of the manner in which the plug may be assembledfrom multiple pieces around the electrical connector.

FIG. 6E is a perspective view of the plug of the inspiratory hoseassembly of FIGS. 6A and 6B showing details of the shaping of the plugimprove the flow of respiratory gases through the inspiratory hoseassembly.

FIG. 6F is an exploded perspective view of the combination of the plugand electrical connector of the expiratory hose assembly of FIG. 6Cshowing details of the manner in which the plug may be assembled frommultiple pieces around the electrical connector.

FIG. 6G is a perspective view of the plug of the expiratory hoseassembly of FIG. 6C showing details of the shaping of the plug improvethe flow of respiratory gases through the inspiratory hose assembly.

FIG. 7A is a partial elevational view of either the inspiratory hoseassembly or the expiratory hose assembly of the embodiment of the heatedrespiratory hose assembly of FIG. 3B.

FIG. 7B is another partial elevational view of either the inspiratoryhose assembly or the expiratory hose assembly of the embodiment of theheated respiratory hose assembly of FIG. 3B showing details of themanner in which the support helix is shaped and positioned within a hosefitting as part of forming a pigtail.

FIG. 7C is a combination of perspective and cross-sectional views of aportion of a pigtail of one of the hoses of either of the embodiments ofheated respiratory hose assembly of any of FIG. 3B or 3C showing detailsof the formation of the pigtail from a portion of an unwound end of asupport helix.

DETAILED DESCRIPTION

FIGS. 1A through 1E, taken together, depict aspects of a novel heatedrespiratory hose assembly 1000 that addresses many of the shortcomingsof prior art assemblies, including those discussed above. As depicted inFIG. 1A, the heated respiratory hose assembly 1000 may include twosub-assemblies, specifically an inspiratory hose assembly 1002 by whichrespiratory gases may be conveyed from a medical device to a patient tobreathe in, and an expiratory hose assembly 1006 by which respiratorygases breathed out by the patient may be conveyed back to the medicaldevice. This circular flow is also conceptually depicted in FIG. 2A.

The inspiratory hose assembly 1002 includes an inspiratory inlet fitting1100 for connection to a medical device 990 (e.g., a ventilator or CPAPdevice), an inspiratory outlet fitting 1300 for connection to a parallelY-fitting 1400 at the patient end, and an inspiratory hose 1200 toconvey respiratory gases received by the inspiratory inlet fitting 1100from the medical device 990 and to the inspiratory outlet fitting 1300to be conveyed onward to the patient through the parallel Y-fitting1400. Correspondingly, the expiratory hose assembly 1006 includes anexpiratory inlet fitting 1500 for connection to the parallel Y-fitting1400 at the patient end, an expiratory outlet fitting 1700 forconnection to the medical device 990, and an expiratory hose 1600 toconvey respiratory gases received by the expiratory inlet fitting 1500from the patient through parallel Y-fitting 1400 and to the expiratoryoutlet fitting 1700 to be conveyed onward to the medical device 990. Atthe patient end, the parallel Y-fitting 1400 may connect the heatedrespiratory hose assembly 1000 to a face mask 940, an endotracheal tube940, a tracheostomy stoma 940 (see FIG. 2A) or other component.

Each of FIGS. 1B and 1C provide a perspective view of one embodiment ofthe heated respiratory hose assembly 1000 in which the inspiratory inletfitting 1100 and the expiratory outlet fitting 1700 are both implementedwith 120-degree Y-fittings in which there is both a straight-throughpath for either gases or wiring to pass from the hoses 1200 and 1600,respectively, and an angled path that branches off from thestraight-through path at a 120-degree angle relative to the connectionsto the hoses 1200 and 1600, respectively. Each of FIGS. 1D and 1Eprovide an exploded perspective view of this embodiment. In thisembodiment, one of the connections of each of the Y-fittings 1100 and1700 is occupied by a plug 1180 and 1780 that carries an electricalconnector 1190 and 1790, respectively. In the depicted variant of thisembodiment, at the inspiratory inlet fitting 1100, the straight-throughconnection (relative to the connection to the inspiratory hose 1200) isoccupied by the plug 1180 that carries the electrical connector 1190 bywhich electric power is able to be provided to a pair of heating wiresincorporated into the support helix of the inspiratory hose 1200, aswill be explained in greater detail. Correspondingly, in this depictedvariant of this embodiment, at the expiratory outlet fitting 1700, the120-degree connection (relative to the connection to the expiratory hose1600) is occupied by the plug 1780 that carries the electrical connector1790 by which electric power is able to be provided to a pair of heatingwires incorporated into the helix of the expiratory hose 1600, as willalso be explained in greater detail.

It should be noted that, despite such a depiction of the use ofparticular ones of the three connections of each of the Y-fittings 1100and 1700 in FIGS. 1A-E as being occupied by plugs carrying electricalconnectors, different connections of the Y-fittings 1100 and 1700 may beso occupied in other variants of the embodiment of the heatedrespiratory hose assembly 1000 of FIGS. 1A-E. Also, and as will bedepicted in subsequent figures, it should be noted that otherembodiments of the heated respiratory hose assembly 1000 may employ hosefitting(s) 1100 and/or 1700 of an entirely different type that may eachprovide a different selection of connections from which one may bechosen to be occupied by a plug carrying an electrical connector.

FIGS. 2A through 2C, taken together, depict aspects of the use ofsensors with at least the inspiratory hose assembly 1002 of the heatedrespiratory hose assembly 1000 to monitor the flow and/or temperature ofat least respiratory gases from the medical device 990 to the patient.As depicted, the inspiratory inlet fitting 1100 may additionally includea flow sensor port 1110 formed through a portion of the wall of theinspiratory inlet fitting 1100. The flow sensor port 1110 provides anopening into the inspiratory interior of the inlet fitting 1100 throughwhich a flow sensor 910 of a sensor harness 902 is able to be insertedto continually confirm the flow of respiratory gases from the medicaldevice 990 and toward the patient at the patient end. As will beexplained in greater detail, the flow sensor 910 is directional innature such that it must be installed within the flow sensor port 1110in a correct orientation to function properly.

As depicted, the inspiratory outlet fitting 1300 may additionallyinclude a temperature sensor port 1330 formed through the wall of theinspiratory outlet fitting 1300. The temperature sensor port 1330provides an opening into the interior of the inspiratory outlet fitting1300 by which a temperature sensor 930 of the sensor harness 902 is ableto be inserted to continually monitor the temperature of the respiratorygases output by the medical device 990 at a location towards the patientend (i.e., just before those respiratory gases are conveyed through theinspiratory outlet fitting 1300 and into the parallel Y-fitting 1400 tobe conveyed onward to the patient).

In some embodiments, and as can best be seen in FIG. 2B, the inspiratoryinlet fitting 1100 may carry a port plug 1112 that may be used to closeand seal the flow sensor port 1110 in situations where at least theinspiratory hose assembly 1002 is used without the flow sensor 910installed within the flow sensor port 1110. Alternatively oradditionally, the inspiratory outlet fitting 1300 may carry a port plug1332 that may similarly be used to close and seal the temperature sensorport 1330 in situations where at least the inspiratory hose assembly1002 is used without the temperature sensor 930 installed within thetemperature sensor port 1330. As depicted, the port plugs 1112 and 1332may be carried by the hose fittings 1100 and 1300, respectively, bybeing attached thereto with elongate stretches of the rigid plasticsmaterial of the hose fittings 1100 and 1300 that are long and thinenough as to be sufficiently flexible that the port plugs 1112 and 1332are able to be maneuvered to and from the ports 1110 and 1330,respectively, for a relatively limited number of times without theelongate stretches breaking.

As also depicted, the flow sensor 910 and the temperature sensor 930 maybe physically connected by a length of cabling 920 of the sensor harness902 that is meant to follow the length of the inspiratory hose 1200, andby which signals of the temperature sensor 930 are conveyed toward thelocation of the flow sensor 910. As can also be seen, there may also beanother length of cabling 920 of the sensor harness 902 that extendsfrom the flow sensor 910 and towards the medical device 990 to conveythe signals of both sensors 910 and 930 to the medical device 990.

Referring more specifically to FIG. 2A, during operation of the medicaldevice 990, respiratory gases to be breathed in by a patient areconveyed from the medical device 990, through the inspiratory inletfitting 1100, then the inspiratory hose 1200, then the inspiratoryoutlet fitting 1300, then the parallel Y-fitting 1400, and then to thepatient via still another component, such as a face mask 940, anendotracheal tube 940, a tracheostomy stoma 940 or other component. Alsoduring operation of the medical device 990, respiratory gases breathedout by the patient are conveyed from the patient through such acomponent (e.g., the face mask 940, the tracheal tube 940, thetracheostomy stoma 940 or other component), then the parallel Y-fitting1400, then the expiratory inlet fitting 1500, then the expiratory hose1600, then the expiratory outlet fitting 1700, and onward to the medicaldevice 990.

While this circular flow of respiratory gases goes on between themedical device 990 and the patient, the medical device 990 monitors theflow sensor 910 to ensure that respiratory gases to be breathed in bythe patient are, in fact, output by the medical device 990 and into theinspiratory hose assembly 1002 of the heated respiratory hose assembly1000 towards the patient. If a lack of flow and/or flow in a wrongdirection is detected by the sensor 910, then the medical device 990 maysound an alarm and/or provide some other audio and/or visual indicationof the lack of flow and/or the incorrect direction of flow. Also whilethis circular flow of respiratory gases goes on between the medicaldevice 990 and the patient, the medical device monitors the temperaturesensor 930 to ensure that the respiratory gases that reach the patientend of the inspiratory hose 1200 are of a correct temperature, both toprevent condensation within the inspiratory hose 1200, and for thehealth of the patient.

Referring more specifically to FIG. 2C, as just discussed, thedirectional nature of the flow sensor 910 requires correct installationof the flow sensor 910 within the interior of the inspiratory inletfitting 1100 to ensure that it is caused to sense the flow ofrespiratory gases towards the patient with a correct orientation.Otherwise, it may be that the flow sensor 910 is caused to at leastattempt to detect a flow of respiratory gases in a direction opposite ofthe correct direction towards the patient. The inspiratory inlet fitting1100 may carry a flow sensor guide 1119 adjacent to the flow sensor port1110 to cooperate with the shape of a portion of the exterior of theflow sensor 910 to aid in correctly positioning the flow sensor 910relative to the flow sensor port 1110 and the interior of theinspiratory inlet fitting 1100. Alternatively or additionally, the flowsensor port 1110 may be formed to include a short tube-like portion witha bevel cut 1111 to interact with an orientation key 911 carried on aportion of the exterior of the flow sensor 910 to aid in correctlypositioning the flow sensor 910 relative to the flow sensor port 1110and the interior of the inspiratory inlet fitting 1100.

The medical device 990 may selectively turn on and off the provision ofelectric power to the heating wires within the inspiratory hose 1200 andthe expiratory hose 1600 to selectively apply heat thereto based on thetemperature sensed by the temperature sensor 930. More specifically, andas will be explained in greater detail, each of the hoses 1200 and 1600may incorporate at least a pair of heating wires that may be connectedto the medical device 990 at one end of each of the hoses 1200 and 1600,and that may be soldered, crimped or otherwise electrically connected atthe other end of each of the hoses 1200 and 1600 to form a separateclosed loop of electric current through each of the hoses 1200 and 1600.

Some medical devices 990 may turn on and off the provision of electricpower to the heating wires of both hoses together. Indeed, some medicaldevices 990 may selectively provide the very same voltage from the verysame power source to the heating wires of both hoses. However, it may bethe case that each of the two hoses 1200 and 1600 are to be heated todifferent temperatures. Thus, the heating wires employed in the twohoses 1200 and 1600 may be of different resistances and/or have otherdiffering characteristics to bring about such a difference intemperature. More specifically, it may be deemed desirable to heat therespiratory gases being conveyed to the patient through the inspiratoryhose 1200 to a higher temperature than the respiratory gases beingconveyed from the patient through the expiratory hose 1600. The heatingof gases conveyed to the patient may be deemed of greater importance forsuch purposes as achieving a particular higher temperature to help thepatient maintain a particular body temperature, aid in treating thepatient for a particular respiratory illness, etc. Such heating of thegases conveyed to the patient would also be intended to preventcondensation from occurring within the inspiratory hose 1200. Incontrast, the heating of gases conveyed from the patient may be solelyfor the purpose of preventing condensation from occurring within theexpiratory hose 1600.

Each of FIGS. 3A through 3C depict another possible embodiment of theheated respiratory hose assembly 1000 in which other possible differentversions (or combinations of versions) of the inspiratory inlet fitting1100 and the expiratory outlet fitting 1700 may be used. FIG. 3Aprovides an exploded perspective view of an alternate embodiment of theheated respiratory hose assembly 1000 in which the inspiratory inletfitting 1100 and the expiratory outlet fitting 1700 are both T-fittings,instead of the 120-degree Y-fittings depicted in FIGS. 1A through 1E.FIG. 3B provides a perspective view of another alternate embodiment ofthe heated respiratory hose assembly 1000 in which the inspiratory inletfitting 1100 and the expiratory outlet fitting 1700 are boththrough-fittings, and from each of which a pigtail 1285 and 1685 emergesby which the electrical connection to the heating wires of the hoses1200 and 1600, respectively, are separately made. FIG. 3C provides aperspective view of the expiratory hose assembly 1006 of still anotherembodiment of the heated respiratory hose assembly 1000 in which atleast the expiratory outlet fitting 1700 is a through-fitting from whichthe pigtail 1685 by which electrical connection is made to the heatingwires of the expiratory hose 1600 emerges in a direction perpendicularto the direction from which the expiratory hose 1600 emerges. Incontrast, the pigtails 1285 and/or 1685 depicted in the embodiment ofFIG. 3B emerge from the hose respective fittings 1100 and/or 1700 in adirection that is parallel to (and alongside) the hoses 1200 and/or1600, respectively.

It should be noted that, despite such depictions of particular alternateembodiments, still other alternate embodiments of the heated respiratoryhose assembly 1000 are possible in which still other types of fittingsare employed as one or both of the inspiratory inlet fitting 1100 andthe expiratory outlet fitting 1700. Further, it should be noted that,despite the depictions of the inspiratory outlet fitting 1300 and of theexpiratory inlet fitting 1500 being unchanged throughout these multipledepicts of differing embodiments of the heated respiratory hose assembly1000, other embodiments are possible in which other types of fittingsmay be employed as one or both of the inspiratory outlet fitting 1300and the expiratory inlet fitting 1500. Further, it should be noted that,despite the depictions of the inspiratory inlet fitting 1100 and theexpiratory outlet fitting 1700 being of the same type, still otherembodiments of the heated respiratory hose assembly 1000 are possible inwhich the inspiratory inlet fitting 1100 and the expiratory outletfitting 1700 are of different types (e.g., one may be a Y-fitting andthe other may be a T-fitting, or one may be a Y-fitting or T-fittingthat carries a plug with an electrical connector and the other may be athrough-fitting with a pigtail that carries another plug).

FIGS. 4A through 4F, taken together, depict various aspects of themaking of the inspiratory hose 1200 and the expiratory hose 1600,including aspects of forming the support helixes 1280 and 1680 thereofto include a pair of heating wires 1290 and 1690, respectively. Itshould be noted that, although the helixes 1280 and 1680 are depicted aseach incorporating a pair of heating wires 1290 and 1690, respectively,other embodiments of the hoses 1200 and/or 1600 are possible in whichdifferent numbers of wires (whether heating wires, or not) may beincorporated into the helixes 1280 and/or 1680, respectively, as well asother embodiments in which there may be multiple helixes that each carryone or more different wires (whether heating wires, or not).

As depicted, each of the hoses 1200 and 1600 may include a wall 1270 and1670, respectively, that is physically supported by a corresponding oneof the support helixes 1280 and 1680. As also depicted, the supporthelixes 1280 and 1680 may spirally wrap around the exterior of the walls1270 and 1670, respectively, in a manner that leaves a continuoushelical stretch of the walls 1270 and 1670 between adjacent coils of thesupport helixes 1280 and 1680 that enable the hoses 1200 and 1600,respectively, to be flexible enough to bend. Additionally, such spacingbetween adjacent coils of the support helixes 1280 and 1680 may be of adistance selected to allow fold(s), curve(s) and/or convolution(s) to beformed in the continuous helical stretch of the walls 1270 and 1670therebetween to enable the hoses 1200 and 1600, respectively, to beaxially stretched and compressed (i.e., lengthened or shortened alongthe depicted axis 101), as well as to bend.

As depicted most clearly in FIG. 4B, the heating wires 1290 and 1690 maybe positioned within the flexible plastics material of the supporthelixes 1280 and 1680 to bring them closer to the interior of the hoses1200 and 1600, respectively, than to the environment external thereto.In this way, much of the flexible plastics material that makes up thesupport helixes 1280 and 1680 is used as insulation to tend to cause theheat generated by the heating wires 1290 and 1690 to be radiated intothe interiors of the hoses 1200 and 1600, respectively, instead of beingwasted by being radiated into the environment external to the hoses 1200and 1600.

As also depicted most clearly in FIG. 4B, each individual heating wire1290 and 1690 may incorporate a conductor 1291 and 1691, and anindividual insulator 1292 and 1692 in addition to the insulationprovided by the flexible plastics material of the support helix 1280 and1680, respectively. In some embodiments, the heating wire 1290 and 1690may be a variant of magnet wire or similar wire with a selectedresistance where the insulator 1292 and 1692, respectively, may be oneor more layers of polymer or other type of film. As will be recognizedby those skilled in the art, the insulators 1292 and 1692 may beselected to be capable of resisting temperatures expected to beencountered during heating of the hoses 1200 and 1600, respectively, butto not be capable resisting temperatures typically encountered duringsoldering such that electrical connections may be made to the wires 1290and 1690 using any of a variety of soldering techniques withoutrequiring stripping of the insulation 1292 and 1692, respectively, inpreparation therefor.

As depicted most clearly in FIGS. 4C and 4D, each of the hoses 1200 and1600 may be formed using a modified variant of a typical hosemanufacturing apparatus 100. As will be familiar to those skilled in theart, such a hose manufacturing apparatus 100 may incorporate a set ofrotating rollers 110 that may be canted in adjustable orientationsrelative to each other and relative to the axis 100 to form a hosetherearound from one or more spirally wound extruded lengths of plasticsmaterial. As will also be familiar to those skilled in the art, suchhose forming typically entails wrapping at least one extruded length ofwebbing material for the wall of the hose and at least one extrudedlength of a support bead for at least one support helix of the hose.Alternatively, a single extrusion of material that combines the webbingand support bead may be used, as will also be familiar to those skilledin the art. An example of such hose manufacturing apparatus is disclosedin U.S. Pat. No. 9,505,164 issued Nov. 29, 2016 to Carl J. Garrett,which is incorporated herein by reference in its entirety, and fromwhich FIG. 1 was copied to provide 4C of this present application.Additional aspects of hose making on which the making of the hoses 1200or 1600 may also be based are disclosed in U.S. Pat. No. 9,308,698issued Apr. 12, 2016 to Martin E. Forrester, and U.S. Pat. No. 9,556,878issued Jan. 31, 2017 to Carl J. Garrett, each of which is incorporatedherein by reference in their entireties. However, to enable the formingof the hoses 1200 and 1600, such a typical hose making apparatus 100 maybe modified to enable the extrusion of the flexible plastics material ofthe support helixes 1280 and 1680 around the heating wires 1290 and1690, respectively, prior to the winding of the support helixes 1280 and1680 onto the rollers 110.

As depicted most clearly in FIGS. 4D and 4F, as part of suchmodifications to the hose making apparatus 100, each of the heatingwires 1290 and/or 1690 around which the plastic material of the helixes1280 and/or 1680, respectively, is extruded may be tensioned (either atthe spool from which each of the heating wires 1290 and/or 1690 areunwound, or with a separate tensioning device between the spool and theextruder 107 b) to cause a “drawing down” of each of the heating wires1290 and/or 1690 through the material of the support helixes 1280 and/or1680, and closer towards the wall 1270 and/or 1670 as the hoses 1200and/or 1600, respectively, are made. Stated differently, when theflexible material of each of the support helixes 1280 or 1680 isextruded around the heating wires 1290 or 1690 that are to be embeddedtherein, the heating wires 1290 or 1690 may initially centered withinthe extruded plastics material. However, as the freshly extruded (andstill somewhat molten and compliant) plastics material of the supporthelix 1280 or 1680 is wound about a set of rotating rods 110 of hosemaking apparatus 100, the tensioner(s) 108 may exert tension on theheating wires 1290 or 1690 to cause the heating wires 1290 or 1690 to bepulled radially inwardly toward the central axis 101 of the hose 1200 or1600 being formed. This may cause the heating wires 1290 or 1690 tomigrate within the flexible plastics material of the support helix 1280or 1680 (again, while still somewhat molten and compliant) to a positionwithin that plastics material that is closer to the interior of the hose1200 or 1600, respectively, being formed than their initially centeredposition.

Turning more specifically to FIG. 4E, as the wall 1270 or 1670 of one ofthe hoses 1200 or 1600 is formed on the rollers 110 of the hose makingapparatus 100, a portion of the support helix 1280 or 1680 is laid downupon the external surface of the wall 1270 or 1670, respectively. Asdepicted, the cross-section of the length of extruded material fromwhich the wall 1270 or 1670 is formed may include a pair of radiallyoutwardly projecting guides to aid in guiding the support helix 1280 or1680 into its proper position on the exterior surface of the wall 1270or 1670, respectively. Turning more specifically to FIG. 4F, andregardless of whether such guide projections are provided, following thelaying down of the portion of the support helix 1280 or 1680 onto theexternal surface of the wall 1270 or 1670, the aforedescribed tensioncauses inward migration of the heating wires 1290 or 1690 within theflexible (and still somewhat molten and compliant) plastics material ofthat portion of the support helix 1280 or 1680 toward the externalsurface of the wall 1270 or 1670 (which may be less molten or no longermolten, which may be used to stop the migration at the external surfaceof the wall 1270 or 1670), toward the interior of the hose 1200 or 1600,and toward the central axis 101 of the hose 1200 or 1600, respectively.

This technique of causing a radially inward draw down may be deemedpreferable to attempting to position the heating wires 1290 and/or 1690within the cross-sections of the extrusions of the helixes 1280 and/or1680 at such locations during extrusion. This technique of causing aradially inward draw down may also provide the flexibility to allowvariations in placement of the heating wires 1290 and/or 1690 furtherradially inward and/or further radially outward within thecross-sections of the helixes 1280 and/or 1680, respectively, as part ofcreating different variants of the hoses 1200 and/or 1600 that may havedifferent heating characteristics (and/or other characteristics that maybe influenced by placement of the heating wires 1290 and/or 1690 withinthe helixes 1280 and/or 1680, respectively).

FIGS. 5A through 5E, taken together, depict various aspects of couplingthe expiratory inlet fitting 1500 to an undermold coupling 1800, andthereby, to one end of the expiratory hose 1600. Stated differently, andas earlier depicted in the exploded perspective views in each of FIGS.1D, 1E and 3A, the expiratory inlet fitting 1500 may be coupled to oneend of the expiratory hose 1600 via the depicted undermold coupling 1800interposed between a portion of the outer surface of that end of theexpiratory hose 1600 and a portion of the inner surface of a hoseinterface 1580 of the expiratory inlet fitting 1500.

The undermold coupling 1800 may include a tubular portion 1881 having acylindrical tubular shape that defines a passage therethrough. At oneend of the tubular shape of the tubular portion 1881 may be a ring 1883that extends radially outward from the cylindrical tubular shape of thetubular portion 1881. Extending from the ring 1883 (or form anotherportion of the external surface of the tubular portion 1881) may be oneor more gratings 1885 that may be defined by one or more parallelelongate portions of the flexible plastics material of the undermoldcoupling 1800 that define one or more parallel slots 1886. Each of theelongate portions of the material that define one of the one or moregratings 1885 may be curved to allow each to extend in a manner thatfollows the curve of the cylindrical shape of the tubular portion 1881.

Each grating 1885 may be supported by, and attached to, the rest of thestructure of the undermold coupling 1800 (e.g., connected to the ringportion 1883, as depicted) by a pair of grating supports 1884 that maycooperate with the grating 1885 to create what may visually resemble aladder. The grating supports may tend to support the one or moregratings 1885 at a location and in an orientation that causes eachgrating 1885 to extend alongside and in parallel with a portion of theexternal surface of the tubular portion 1881. While each grating 1885 isso positioned by one or more of the grating supports 1884, inwardlyfacing surfaces 1888 of each of the one or more curved elongate portionsof flexible plastics material that defines each of the gratings 1885 maytend to be positioned in contact with the portion of the externalsurface of the tubular portion 1881 that its corresponding grating 1885overlies. Being formed of the flexible plastics material of theundermold coupling 1800, the grating supports 1884 may each be flexibleenough to allow each of the gratings 1885 to be pulled away from itsposition extending alongside and parallel with a portion of the externalsurface of the tubular portion 1881 (thereby pulling the inwardly facingsurfaces thereof out of contact with the external surface of the tubularportion 1881.

The hose interface of the expiratory inlet fitting 1500 may incorporateone or more gratings 1586 that are meant to correspond to the one ormore gratings 1885 carried by the undermold coupling 1800. Each of theone or more gratings 1586 may be defined by one or more parallelelongate portions of the rigid plastics material of the expiratory inletfitting 1500 that define one or more parallel slots 1585 that may havethe appearance of a set of one or more vent slots formed through thewall of the expiratory inlet fitting 1500. Each of the elongate portionsof the material that define one of the one or more gratings 1586 may becurved to allow each to extend in a manner that parallels the curve ofthe cylindrical shape of the tubular portion 1881. Additionally, the oneor more parallel elongate portions of the material of the expiratoryfitting 1500 that define one of the one or more gratings 1586, and theone or more slots 1585 defined thereby, may be intersected by one ormore troughs 1584 formed in the cylindrical external surface of theexpiratory inlet fitting 1500 to receive a corresponding one or more ofthe grating supports 1884.

As depicted most clearly in FIGS. 5A, 5B, 5D and 5E, the undermoldcoupling 1800 may include threads 1882 formed on the inner surface ofthe tubular portion 1881 to receive and surround the external surface ofone end of the expiratory hose 1600 in a manner that engages the wall1670 and the support helix 1680 thereof as if the wall 1670 and helix1680, together, formed matching threads as a mechanism by which theundermold coupling 1800 may grip that end of expiratory hose 1600 withinthe tubular portion 1881. In some embodiments, the tubular portion 1881of the undermold coupling 1800 may be threaded onto an end of theexpiratory hose 1600.

Turning more specifically to FIGS. 5B and 5C, with the undermoldcoupling 1800 so threaded onto an end of the expiratory hose 1600, thatend of the expiratory hose 1600 may be inserted into the hose interface1580 of the expiratory inlet fitting 1500. As a result, the tubularportion 1881 of undermold coupling 1800 is inserted into the hoseinterface 1580 and becomes interposed between the external surface ofthat end of the expiratory hose 1600 and the internal surface of thehose interface 1580 of the expiratory inlet fitting 1500. As depicted inmost clearly in FIGS. 5B and 5C, as such insertion occurs, each grating1885 of the undermold coupling 1800 may be pulled away from the tubularportion 1881 (relying on the flexibility of the grating supports 1884 toact somewhat like hinges) and caused to extend over exterior portions ofthe expiration inlet fitting 1500 in the vicinity of the hose interface1580. With each grating 1885 so positioned over its correspondinggrating 1586, the grating 1885 may then be allowed to return to aposition alongside and parallel to the external surface of the tubularportion 1881 of the undermold coupling 1800.

As depicted most clearly in FIG. 5D, with the each of the gratings 1885allowed to return to a position alongside and parallel to the externalsurface of the tubular portion 1881 while each of the gratings 1885 ispositioned over its corresponding grating 1586, the corresponding onesof the one or more gratings 1885 and 1586 are caused to intermesh in amanner that mechanically locks the undermold coupling 1800 within thehose interface 1580. More specifically, in each such interlock between acorresponding pair of gratings 1885 and 1586, each of the elongateportions of a grating 1885 of the undermold coupling 1800 extends into acorresponding slot 1585 defined by the corresponding grating 1586 of theexpiratory inlet fitting 1500, and each of the elongate portions of thatcorresponding grating 1586 extends into a corresponding slot 1886defined by the grating 1885.

As a result, the inwardly facing surfaces 1888 of each of the one ormore curved elongate portions of the flexible plastics material of theundermold coupling that define each of the gratings 1885 is allowed tobe brought back into contact with a portion of the external surface ofthe tubular portion 1881, as most clearly depicted in FIG. 5D. With suchsurface contacts once again made, while the one or more correspondingpairs of the gratings 1885 and 1586 are so intermeshed, heat may beapplied to soften at least the undermold coupling 1800 to cause theinwardly facing surfaces 1888 of those portions of the one or moregratings 1885 that are once again in contact with the external surfaceof the tubular portion 1881 to become bonded to the exterior of thetubular portion 1881, as most clearly depicted in FIG. 5E. Such heatingmay also more broadly bond the materials of the thread-like exterior ofthe end of the expiratory hose 1600 (onto which the undermold coupling1800 is threaded) to surfaces of the threads 1882 formed within theundermold coupling 1800, and such heating may also more broadly bond thematerial of the exterior surface of the tubular portion 1881 of theundermold coupling 1800 to the interior surface of the expiration inletfitting 1500 into which the undermold coupling 1800 is inserted. As aresult, gas-tight seals may be formed among these components.

In other embodiments, an end of the expiratory hose 1600 may be insertedinto the hose interface 1580 of the expiratory inlet fitting 1500without an undermold coupling 1800 threaded thereon. After suchinsertion, the flexible material of the undermold coupling 1800, inmolten form, may be injected into one or more of the slots 1585 of oneor more gratings 1586 of the hose interface 1580 to fill the spacebetween the thread-like external surface of that end of the expiratoryhose 1600 and the interior surface of the hose interface 1580 to formthe undermold coupling 1800 in place therebetween, as well as to filleach of the slots 1585. Alternatively, the flexible material of theundermold coupling 1800, in molten form, may be injected therein betweenthe expiratory hose 1600 and the edge of the interior surface of thehose interface 1580, where the expiratory hose 1600 enters into the hoseinterface 1580, to form the undermold coupling 1800 in place, as well asto fill each of the slots 1585 from within the interior of the hoseinterface 1580. Regardless of the exact manner in which the molten formof the material of the undermold coupling 1800 is injected to form theundermold coupling 1800 in place, in so forming the undermold coupling1800 in place, the molten form of the undermold coupling 1800 may bondto the materials of thread-like external surface at the end of theexpiratory hose 1600 and the interior surface of the hose interface 1580to form a gas-tight seal therebetween.

It should be noted that although FIGS. 5A through 5E depict thesefeatures in a manner that is focused on the connection of an end of theexpiratory hose 1600 to the expiratory inlet fitting 1500, the very samecoupling arrangement just described may be employed to couple the otherend of the expiratory hose 1600 to the expiratory outlet fitting 1700,and/or one or both ends of the inspiratory hose 1200 to one or both ofthe inspiratory inlet fitting 1100 and the inspiratory outlet fitting1300. Stated differently, and as depicted most clearly in each of FIGS.1D, 1E and 3A, multiple ones of the undermold coupling 1800 may beemployed to couple each of the fittings 1100 and 1300 to opposite endsof the inspiratory hose 1200, and to couple each of the fittings 1500and 1700 to opposite ends of the expiratory hose 1600.

FIGS. 6A through 6G, taken together, depict various aspects ofincorporating the plug 1180 or 1780 incorporating the electricalconnector 1190 or 1790 into one of the three connections provided by theinspiratory inlet fitting 1100 or the expiratory outlet fitting 1700,respectively. Also depicted are various aspects of the direct electricalcoupling of the heating wires 1290 or 1690 to the electrical connector1190 or 1790, respectively.

Each of FIGS. 6A and 6B depicts a subset of the components of theinspiratory hose assembly 1002 toward the end thereof that is to beconnected to the medical device 990. More precisely, FIGS. 6A and 6Beach depict the path followed by the support helix 1280 within theinspiratory hose 1200 and where an end of the inspiratory hose 1200 iscoupled to the inspiratory inlet fitting 1100. The wall 1270 of theinspiratory hose 1200 has been omitted in both of these views forpurposes of visual clarity. Additionally, in FIG. 6B, both the plug 1180and the insulating shroud portion of the electrical connector 1190 havebeen omitted, also for purposes of visual clarity. As depicted, where anend of a portion of the inspiratory hose 1200 is inserted into a portionof the inspiratory inlet fitting 1100, a relatively short portion of thesupport helix 1280 is unwound from its helical path within theinspiratory hose 1200 and is employed as an electrical cable to bringthe heating wires 1290 therein to the electrical connector 1190 withinthe plug 1180.

More specifically, a relatively short portion of the support helix 1280is pulled out of the end of the inspiratory hose 1200 (i.e., unwoundtherefrom) where that end is inserted into the inspiratory inlet fitting1100, and straightened to at least some degree for use as an electricalcable to bring the heating wires 1290 therein directly to the electricalconnector 1190. This unwinding of the relatively short portion of thesupport helix 1280 may be performed prior to the threading of thedepicted undermold coupling 1800 onto the end of the inspiratory hose1200 that is to be inserted into the inspiratory inlet fitting 1100. Asa result, the relatively short unwound portion of the support helix 1280extends beyond the end of the inspiratory hose 1200 onto which theundermold coupling 1800 is threaded, thereby emerging from within theundermold coupling 1800 and extending further into the interior of theinspiratory inlet fitting 1100 than the end of the inspiratory hose 1200onto which the undermold coupling 1800 is threaded.

The end of the relatively short portion of the support helix 1280 thatextends toward the electrical connector 1190 may be partly stripped awayto remove at least enough of the flexible plastics material of thesupport helix 1280 to expose enough of the heating wires 1290 therein toenable forming an electrical connection with the contacts 1199 of theelectrical connector 1190. More precisely, the plastics material of thesupport helix 1280 may be stripped away in a manner that may be akin toprocedures often used in preparing conventional multi-conductor cablesfor the connection of the individual wires therein to contacts of anelectrical connector or other electrical device. Thus, typical wirestripping techniques may be employed to gain access to each of theheating wires 1290, and then the conductor 1299 (see FIG. 4B) withineach of the heating wires 1290 may be soldered to a soldering tab of oneof the electrical contacts 1199 of the electrical connector 1190.Additionally, if the relatively short unwound portion of the supporthelix 1280 is additionally covered in a sheath (e.g., heatshrink tubingthat may be sleeved over the relatively short unwound portion of thesupport helix 1280), then part of that sheath may also be similarlystripped away using typical wire stripping techniques. As previouslydiscussed, the conductor 1299 of each of the heating wires 1290 may besheathed within an individual insulator 1291 that is selected to bethermally resistant to the temperatures expected to be encounteredduring heating of the inspiratory hose 1200, but not to the temperaturesexpected to be encountered during soldering, thereby eliminating theneed to strip each of the conductors 1299 of their individual insulators1291 prior to soldering each of the conductors 1299 to a soldering tabof one of the electrical contacts 1199.

In separating the relatively short portion of the support helix 1280from the inspiratory hose 1200, portions of the wall 1270 (again, notshown for purposes of visual clarity) that extend between adjacent coilsof the support helix 1280 that are included in the relatively shortportion thereof may be trimmed away. After being so separated, therelatively short unwound portion of the support helix 1280 may be heatedto soften the flexible plastics material thereof (i.e., to relax themolecules of the flexible plastics material thereof) to aid instraightening it out from its original helical path within theinspiratory hose 1200 (i.e., causing the molecules of the flexibleplastics material of the relatively short portion of the support helix1280 to adopt a straightened path as a new resting state).

The actual length of the relatively short portion of the support helix1280 that emerges from the undermold coupling 1800 and extends furtherinto the interior of the inspiration inlet fitting 1100 may be based, atleast in part, on the dimensions of the inspiration inlet fitting 1100.More specifically, the length may be selected based on the length neededto extend from the undermold coupling 1800 and to the electricalconnector 1190, and may include a predetermined additional length neededto allow manufacturing personnel sufficient physical access to solderthe conductors 1299 of the heating wires 1290 to the soldering tabs ofthe electrical contacts 1199, as earlier described.

In a manner somewhat similar to FIGS. 6A and 6B, FIG. 6C depicts asubset of the components of the expiratory hose assembly 1006 toward theend thereof that is to be connected to the medical device 990. Moreprecisely, FIG. 6C depicts the path followed by the support helix 1680within the expiratory hose 1600 and where an end of the expiratory hose1600 is coupled to the expiratory outlet fitting 1600. The wall 1670 ofthe expiratory hose 1600, the plug 1780 and the insulating shroudportion of the electrical connector 1790 have all been omitted forpurposes of visual clarity. As depicted, where an end of a portion ofthe expiratory hose 1600 is inserted into a portion of the expiratoryoutlet fitting 1700, a relatively short portion of the support helix1680 is unwound from its helical path within the expiratory hose 1600and is employed as an electrical cable to bring the heating wires 1690therein to the electrical connector 1790 within the plug 1780 (again,not shown).

More specifically, a relatively short portion of the support helix 1680is pulled out of the end of the expiratory hose 1600 (i.e., unwoundtherefrom) where that end is inserted into the expiratory outlet fitting1700, and straightened to at least some degree for use as an electricalcable to bring the heating wires 1690 therein directly to the electricalconnector 1790. In a manner similar to what was discussed aboveconcerning the support helix 1280, this unwinding of the relativelyshort portion of the support helix 1680 may be performed prior to thethreading of another of the undermold couplings 1800 onto the end of theexpiratory hose 1600 that is to be inserted into the expiratory outletfitting 1700. As a result, the relatively short portion of the supporthelix 1680 extends beyond the end of the expiratory hose 1600 onto whichthe undermold coupling 1800 is threaded, thereby emerging from withinthe undermold coupling 1800 and extending further into the interior ofthe expiratory outlet fitting 1700 than the end of the expiratory hose1600 onto which the undermold coupling 1800 is threaded.

As with the earlier discussed relatively short portion of the supporthelix 1280 employed as an electrical cable, the end of the relativelyshort unwound portion of the support helix 1680 that extends toward theelectrical connector 1790 may also be partly stripped away to remove atleast enough of the flexible plastics material of the support helix 1680to expose enough of the heating wires 1690 therein to enable forming anelectrical connection with the contacts 1199 of the electrical connector1190. Again, this may also be done using typical wire strippingtechniques, and again, if the stripped-away part of the unwound portionof the support helix 1680 is additionally covered in a sheath (e.g.,heatshrink tubing), part of that sheath may also be similarly strippedaway using typical wire stripping techniques. Also again, in separatingthe relatively short portion of the support helix 1680 from theexpiratory hose 1600, portions of the wall 1670 (again, not shown forpurposes of visual clarity) that extend between adjacent coils of thesupport helix 1680 that are included in the relatively short portionthereof may be trimmed away. And again, after being so separated, therelatively short portion of the support helix 1680 may be heated tosoften the flexible plastics material thereof to aid in straightening itout from its original helical path within the expiratory hose 1600.

As with the earlier discussed relatively short portion of the supporthelix 1280 employed as an electrical cable, the actual length of therelatively short portion of the support helix 1680 that emerges from theundermold coupling 1800 and extends further into the interior of theexpiration outlet fitting 1700 may be based, at least in part, on thedimensions of the expiration outlet fitting 1700. More specifically, thelength may be selected based on the length needed to extend from theundermold coupling 1800 and to the electrical connector 1790, and mayinclude a predetermined additional length needed to allow manufacturingpersonnel sufficient physical access to solder the conductors 1699 ofthe heating wires 1690 to the soldering tabs of the electrical contacts1799.

Such use of a portion of the support helixes 1280 and/or 1680, as ifeach were a conventional two-conductor electric cable, advantageouslyavoids the creation of electrical terminations where a transition ismade between the heating wires 1290 and/or 1690 of the support helixes1280 and/or 1680 to non-heating wires that travel a relatively shortdistance within the fittings 1100 and/or 1300 to electrically couple theheating wires 1290 and/or 1690 to the electrical connectors 1190 and/or1790, respectively. Experience has shown that such electricalterminations to transition between heating and non-heating wires can bea source of potentially dangerous electrical failures. Poorlyimplemented electrical terminations of this type can actually have ahigher resistance than the heating wires 1290, themselves, such that theterminations can become hotter than either the heating wires 1290 or1690. This may lead to such hazards as burning through the plasticsmaterial of the inspiratory inlet fitting 1100 and/or otherwisegenerating toxic smokes/gases within the inspiratory inlet fitting 1100that may be inhaled by the patient. It has been discovered throughtesting that such a transition between heating and non-heating wires isunnecessary, and that portions of the support helixes 1280 and 1680 canbe used as multi-conductor cables, as has been described.

FIGS. 6D and 6E, taken together, depict various features of the plug1180 and the electrical connector 1190 carried therein. As depicted, insome embodiments, the plug 1180 may be formed from multiple separatelyfabricated plastic components, including the depicted face portion 1181and the depicted pair of “clamshell” portions 1182. In this depictedembodiment, much of the electrical connector 1190 (with its electricalcontacts 1199 installed therein, and already soldered to the conductors1299 of the heating wires 1290 of the support helix 1280) may beenclosed between the two clamshell portions 1182, which may be fastenedto each other in any of a variety of ways. A portion of the supporthelix 1280 adjacent the electrical connector 1190 may also be enclosedbetween the two clamshell portions 1182. The face portion 1181 may thenbe molded over the assembled pair of the clamshell portions 1182 withthe electrical connector 1190 enclosed between the clamshell portions1182. In so molding the face portion 1181, portions of the plasticsmaterial of the face portion 1181, while in a molten state, may fillvarious convolutions formed within each of the two clamshell portions1182 to further bond them together. In so doing, the face portion 1181may also seal spaces between the two clamshell portions 1182 withinwhich the electrical connector 1190 is held, as well as the portion ofthe support helix that is also enclosed therebetween. In so doing, theelectrical connections between the conductors 1299 of the heating wires1290 and the electrical contacts 1199 of the electrical connector 1190may be entirely enclosed to seal and protect those connections againstmoisture present in the respiratory gases conveyed through theinspiratory inlet fitting 1100 to thereby prevent corrosion, etc.

Alternatively, in other embodiments, following the connection of theconductors 1299 of the heating wires 1290 of the support helix 1280 tothe electrical contacts 1199 of the electrical connector 1190, theentire plug 1180 may simply be molded around the electrical connector1190. A portion of the support helix 1280 adjacent the electricalconnector 1190 may also be enclosed within such a molded form of theplug 1180.

Regardless of the exact manner in which the plug 1180 is formed and/orin which the electrical connector 1190 is caused to be enclosed withinthe plug 1180, the portion of the plug 1180 that extends furthest intothe inspiration inlet fitting 1100 may be shaped to cooperate withinterior surface portions of the inspiration inlet fitting 1100 topresent a relatively unobstructed path for the flow of respiratory gasesthrough the inspiration inlet fitting 1100 with relatively smoothsurfaces encountered by the respiratory gases throughout that path. Moreprecisely, and as best seen in FIG. 6E, as well as in FIGS. 1D, 1E and6A, the portion of the plug 1180 that extends furthest into theinspiration inlet fitting 1100 may be provided with a concave surface1183 that serves to define part of such a relatively unobstructed pathwith smooth surfaces for the flow of respiratory gases.

FIGS. 6F and 6G, taken together, depict similar features of the plug1780 and the electrical connector 1790 carried therein. As depicted, insome embodiments, the plug 1780 may be formed from multiple separatelyfabricated plastic components, including the depicted face portion 1781and the depicted pair of clamshell portions 1782. In this depictedembodiment, much of the electrical connector 1790 (with its electricalcontacts 1799 installed therein, and already soldered to the conductors1699 of the heating wires 1690 of the support helix 1680) may beenclosed between the two clamshell portions 1782, which may be fastenedto each other in any of a variety of ways. A portion of the supporthelix 1680 adjacent the electrical connector 1790 may also be enclosedbetween the two clamshell portions 1782. The face portion 1781 may thenbe molded over the assembled pair of the claims clamshell portions 1782to form the plug 1780 with the electrical connector 1790 sealed in placetherein in a manner similar to what has been previously described inreference to the plug 1180.

Alternatively, in other embodiments, following the connection of theconductors 1699 of the heating wires 1690 of the support helix 1680 tothe electrical contacts 1799 of the electrical connector 1790, theentire plug 1780 may simply be molded around the electrical connector1790. A portion of the support helix 1680 adjacent the electricalconnector 1790 may also be enclosed within such a molded form of theplug 1780.

As with the plug 1180, regardless of the exact manner in which the plug1780 is formed and/or in which the electrical connector 1790 is causedto be enclosed within the plug 1780, the portion of the plug 1780 thatextends furthest into the expiration outlet fitting 1700 may be shapedto cooperate with interior surface portions of the expiration outletfitting 1700 to present a relatively unobstructed path for the flow ofrespiratory gases through the expiration outlet fitting 1700 withrelatively smooth surfaces encountered by the respiratory gasesthroughout that path. More precisely, and as best seen in FIG. 6G, aswell as in FIGS. 1D and 1E, the portion of the plug 1780 that extendsfurthest into the inspiration inlet fitting 1700 may be provided with aconcave surface 1783 that serves to define part of such a relativelyunobstructed path with smooth surfaces for the flow of respiratorygases.

It should be noted that, as depicted in FIGS. 6D and 6F, as well asthroughout others of the figures in this present application, theelectrical connectors 1190 and 1790 may be provided with differingphysical shapes as a keying mechanism to prevent incorrect electricalconnections between the medical device 990 and each of the heating wires1290 and 1690 within the hoses 1200 and 1600, respectively. Morespecifically, the electrical connector 1190 is depicted as being aso-called “monkey face” connector having a shape that includes threelobes in which two of the lobes are each occupied by one of theelectrical contacts 1199. In contrast, the electrical connector 1790 isdepicted as having a more conventional elongate oval-like shape in whichthe electrical contacts 1799 are positioned toward opposite ends of theof the oval-like shape. As will be familiar to those skilled in the artof such medical devices as ventilators and CPAP devices, this depictedcombination of forms of the electrical connectors 1190 and 1790 havebecome widely adopted for use in providing electric power for heatingthe hoses used with such medical devices.

As previously discussed, at the opposite end of the support helix 1280from the end that is connected to the electrical connector 1190, theconductors 1299 of the pair of heating wires 1290 may be electricallyconnected to each other through crimping, soldering, etc., to form anelectrical loop with the pair of heating wires 1290 through the supporthelix 1280 for heating the interior of the inspiration hose 1200.Similarly, at the opposite end of the support helix 1680 from the endthat is connected to the electrical connector 1790, the conductors 1699of the pair of heating wires 1690 may be similarly electricallyconnected to each other to form a separate electrical loop with the pairof heating wires 1690 through the support helix 1680 for separatelyheating the interior of the expiration hose 1600. As also previouslydiscussed, the medical device 990 may operate each of these electricalloops separately and in different ways that may be selected to causediffering degrees of heating within each of the hoses 1200 and 1600.Indeed, as also previously discussed, the heating wires 1290 and 1690may be selected to have different resistances in recognition of suchdifferences in the manner in which each may be used.

FIGS. 7A through 7C, taken together, depict various aspects of formingan electrical “pigtail” 1285 or 1685 from a portion of the support helix1280 or 1680 for use in connecting the heating wires 1290 or 1690 to themedical device 990 to be provided with electrical power therefrom. In amanner similar to the embodiments depicted and discussed in reference toFIGS. 6A through 6G, FIGS. 7A through 7C present embodiments of the useof a portion of the support helix 1280 or 1680 as an electrical cable toadvantageously avoid the creation of a electrical terminations where atransition is made between the heating wires 1290 or 1690, respectively,to non-heating wires. However, unlike the embodiments of FIGS. 6Athrough 6G in which the connector 1190 or 1790 is carried within theplug 1180 or 1780 installed within the fitting 1100 or 1700,respectively, in the embodiments of FIGS. 7A through 7C, the connector1190 or 1790 is located in the environment external to the fitting 1100or 1700 at the end of an electrical pigtail 1285 or 1685, respectively.

Each of FIGS. 7A through 7C depicts a subset of the components of eitherthe inspiratory hose assembly 1002 or the expiratory hose assembly 1006toward the end thereof that is to be connected to the medical device990. More precisely, in each of FIGS. 7A through 7C, depictions of oneof the undermold couplings 1800, and of the wall 1270 or 1670 of thehose 1200 or 1600 has been omitted to enable the helical path of thesupport helix 1280 or 1680, respectively, therein to be viewed moreclearly. Additionally, in FIG. 7B, the depiction of either theinspiratory inlet fitting 1100 or the expiratory outlet fitting 1700that is provided in FIG. 7A is also omitted to provide an uninterruptedview of the transition of the support helix 1280 or 1680 from itshelical path for purposes of heating the interior of the hose 1200 or1600 to a relatively straightened path for purposes of being used as anelectrical cable to convey the heating wires 1290 or 1690 thereof to theconnector 1190 or 1790.

Turning more specifically to FIGS. 7A and 7B, as depicted, where an endof a portion of the inspiratory hose 1200 is inserted into a portion ofthe inspiratory inlet fitting 1100, or where an end of a portion of theexpiratory hose 1600 is inserted into a portion of the expiratory outletfitting 1700, a portion of the support helix 1280 or 1680 is unwoundfrom its helical path within the inspiratory hose 1200 or 1600 and isemployed as an electrical cable to bring the heating wires 1290 or 1690therein to the electrical connector 1190 or 1790 at an end of theelectrical pigtail 1285 or 1685, respectively.

More specifically, a portion of the support helix 1280 or 1680 is pulledout of the end of the hose 1200 or 1600 (i.e., unwound therefrom) wherethat end is inserted into the fitting 1100 or 1700, respectively. Thelength of the unwound portion of the support helix 1280 or 1680 may bedetermined, at least in part, by the intended length of the electricalpigtail 1285 or 1685. The unwound portion of the support helix 1280 or1680 may then be straightened to at least some degree for use as anelectrical cable. This unwinding of the portion of the support helix1280 may be performed prior to the threading of the depicted undermoldcoupling 1800 (again, not shown for purposes of visual clarity) onto theend of the hose 1200 or 1600 that is to be inserted into the fitting1100 or 1700, respectively. As a result, the unwound portion of thesupport helix 1280 extends beyond the end of the 1200 or 1600 onto whichthe undermold coupling 1800 is threaded, thereby emerging from withinthe undermold coupling 1800 and extending further into the interior ofthe 1100 or 1700 than the end of the hose 1200 or 1600, respectively,onto which the undermold coupling 1800 is threaded. The unwound portionof the support helix 1280 or 1680 may then be fed through a channeland/or opening defined by a portion of the fitting 1100 or 1700 to becaused to extend into the environment external to the fitting 1100 or1700 to serve as the core of the electrical pigtail 1285 or 1685.

Turning briefly to FIG. 7C, as depicted, the unwound portion of thesupport helix 1285 or 1685 may be covered in a sheath 1281 or 1681, atleast where the unwound portion of the support helix 1285 or 1685emerges from the fitting 1100 or 1700, respectively, and into theenvironment external thereto. Alternatively or additionally, the sheath1281 or 1681 may cover at least part of the unwound portion of thesupport helix 1285 or 1685 within the fitting 1100 or 1700. In someembodiments, the sheath 1281 or 1681 may be a length of heatshrinktubing that is sleeved over the unwound portion of the support helix1285 or 1685 (at least the length thereof that is within the environmentexternal to the fitting 1200 or 1600), and then heated to cause thecross-section of the heatshrink tubing to shrink radially inward towardthe exterior of the unwound portion of the support helix 1285 or 1685.Such an application of heat may also be used to aid in the straighteningof the unwound portion of the support helix 1280 or 1680 and/or tosomewhat change the shape thereof to conform to the interior surface ofthe heatshrink tubing as the heatshrink tubing is caused to tightlysurround the unwound portion of the support helix 1285 or 1685,respectively (at least the length thereof that is within the environmentexternal to the fitting 1200 or 1600).

Turning again more specifically to FIGS. 7A AND 7B, the end of theunwound portion of the support helix 1280 or 1680 that extends towardthe electrical connector 1190 or 1790 may be partly stripped away toremove at least enough of the flexible plastics material of the supporthelix 1280 or 1680 (and maybe also to strip away a portion of the sheath1281 or 1681) to expose enough of the heating wires 1290 or 1690 thereinto enable forming an electrical connection with the contacts 1199 or1799 of the electrical connector 1190 or 1790, respectively. Again, thismay also be done using typical wire stripping techniques. Also again, inseparating the relatively short portion of the support helix 1280 or1680 from the hose 1200 or 1600, portions of the wall 1270 or 1670(again, not shown for purposes of visual clarity) that extend betweenadjacent coils of the support helix 1280 or 1680 that are included inthe unwound portion thereof may be trimmed away.

It has been discovered through testing that a transition from theheating wires 1290 or 1690 of the support helix 1280 or 1680, and tonon-heating wires to form the electrical pigtail 1285 or 1685 isunnecessary, especially where the electrical pigtail 1285 or 1685additionally includes the sheath 1281 or 1681 to provide additionalinsulation against the heat that may be generated within the electricalpigtail 1285 or 1685 by the heating wires 1290 or 1690, respectively,therein.

Although the invention has been described in a preferred form with acertain degree of particularity, it is understood that the presentdisclosure of the preferred form has been made only by way of example,and that numerous changes in the details of construction and the mannerof manufacture may be resorted to without departing from the spirit andscope of the invention. It is intended to protect whatever features ofpatentable novelty exist in the invention disclosed.

The invention claimed is:
 1. A method of forming a heated hosecomprising: extruding a continuous web of plastics material ofsubstantially uniform width from a first extruder of a hose makingapparatus; helically winding the extruded web about a mandrel or atleast one rotating rod of the hose making apparatus to form a wall ofthe heated hose about a central axis of the heated hose; feeding a firstheating wire into a second extruder of the hose making apparatus;extruding a first continuous bead of plastics material around the firstheating wire from the second extruder of the hose making apparatus suchthat the first extruded bead emerges from the second extruder with thefirst heating wire at a first location within a cross-section of thefirst extruded bead such that the first heating wire is fully surroundedby the plastics material of the first extruded bead; helically windingthe first extruded bead onto and about an external surface of the wallof the hose formed from the helical winding of the extruded web toprovide the wall a first support helix that incorporates the firstheating wire; and exerting tension on the first heating wire as thefirst heating wire is fed into the second extruder, and as the firstextruded bead is wound onto and about the external surface of the wallof the hose, to draw down the first heating wire toward the central axisof the hose such that the first heating wire migrates radially inwardwithin the first extruded bead from the first location already withinthe cross-section of the first extruded bead to a second location thatis still within the cross-section of the first extruded bead, and thatis closer to the external surface of the wall of the hose and closer tothe central axis than the first location within the cross-section of thefirst extruded bead.
 2. The method of claim 1, wherein: thecross-section of the extruded web include a pair of guide formationsthat extend radially outward from the wall of the hose after theextruded web is helically wound about the mandrel or the at least onerotating rod; and the method further comprises using the pair of guideformations to guide the placement of the first extruded bead on the wallas the first extruded bead is helically wound about the wall.
 3. Themethod of claim 1, further comprising helically winding the firstextruded bead about the wall of the hose to provide a predeterminedamount of space between adjacent coils of the first support helix toallow a fold, a curve or a convolution to be formed in stretches of thewall between the adjacent coils of the first support helix to enable thehose to bend or to be axially compressed along the central axis.
 4. Themethod of claim 1, wherein the hose making apparatus comprises atensioner incorporated into a spool of the first heating wire orinterposed between the spool of the first heating wire and the secondextruder to perform the exertion of tension on the first heating wire.5. The method of claim 4, further comprising adjusting the tensionexerted on the first heating wire as the hose is formed to vary thesecond location of the heating wire radially relative to the centralaxis within the first support helix.
 6. The method of claim 1, wherein:when the first extruded bead is helically wound onto and about theexternal surface of the wall of the hose, the first extruded bead is ina molten state that enables the first heating wire to migrate within thefirst extruded bead, and the wall of the hose is not in a molten statethat would enable the first heating wire to migrate through the externalsurface of the wall of the hose such that the external surface of thewall is able to stop the radially inward migration of the first heatingwire within the first extruded bead at the external surface of the wall;and the method comprises: exerting the tension on the first heating wireto cause radially inward migration of the first heating wire through theplastics material of the first extruded bead and onto the externalsurface of the wall; and relying on the external surface of the wallbeing not in a molten state to stop the radially inward migration of thefirst heating wire.
 7. The method of claim 1, further comprising:feeding a second heating wire into the second extruder; extruding thefirst extruded bead of plastics material around both the first heatingwire and the second heating wire from the second extruder such that thefirst extruded bead comprises both the first heating wire at the firstlocation within the cross-section of the first extruded bead and thesecond heating wire at a third location within the cross-section of thefirst extruded bead; and exerting tension on the second heating wire asthe second heating wire is fed into the second extruder to draw down thesecond heating wire toward the central axis of the hose such that thesecond heating wire migrates radially inward within the first extrudedbead from the third location within the cross-section of the firstextruded bead to a fourth location within the cross-section of the firstextruded bead that is closer to the wall of the hose and closer to thecentral axis than the third location.
 8. The method of claim 7, wherein:the first heating wire comprises a first conductor sheathed by a firstinsulator; and the second heating wire comprises a second conductorsheathed by a second insulator.
 9. The method of claim 8, comprisingconnecting the first conductor directly to the second conductor at oneend of the hose to form an electric loop by which the first heating wireand the second heating may be caused to cooperate to heat an interior ofthe hose by the provision of electric power to the first heating wireand the second heating wire at an opposite end of the hose.
 10. Themethod of claim 1, further comprising: feeding a second heating wireinto a third extruder of the hose making apparatus; extruding a secondextruded bead of plastics material around the second heating wire fromthe third extruder such that the second extruded bead comprises thesecond heating wire at a third location within a cross-section of thesecond extruded bead; helically winding the second extruded bead ontoand about the external surface of the wall of the hose to provide thewall a second support helix that incorporates the second heating wire;and exerting tension on the second heating wire as the second heatingwire is fed into the third extruder to draw down the second heating wiretoward the central axis of the hose such that the second heating wiremigrates radially inward within the second extruded bead from the thirdlocation within the cross-section of the second extruded bead to afourth location within the cross-section of the second extruded beadthat is closer to the wall of the hose and closer to the central axisthan the third location.
 11. The method of claim 1, further comprising;cutting the hose into multiple segments of the hose wherein each segmentof the hose is cut to a length selected to be longer than needed toprovide an extra length of the hose within each segment; unwinding aportion of the first support helix from the extra length of the hosewithin each segment; heating the unwound portion of each segment tostraighten the unwound portion; stripping part of an end of the unwoundportion of each segment to expose the first heating wire; and directlyconnecting the first heating wire of each segment to an electricalcontact of an electrical connector to enable the first heating wire tobe operated to heat an interior of the segment of the hose.
 12. A methodof forming a heated hose comprising: extruding a continuous web ofplastics material of substantially uniform width from a first extruderof a hose making apparatus; helically winding the extruded web about amandrel or at least one rotating rod of the hose making apparatus toform a wall of the heated hose about a central axis of the heated hose;feeding a first heating wire and a second heating wire into a secondextruder of the hose making apparatus; extruding a continuous bead ofplastics material around the first heating wire and the second heatingwire from the second extruder of the hose making apparatus such that theextruded bead emerges from the second extruder with the first heatingwire at a first location within a cross-section of the extruded bead andthe second heating wire at a third location within a cross-section ofthe extruded bead such that the first heating wire and the secondheating wire are both fully surrounded by the plastics material of theextruded bead; helically winding the extruded bead onto and about anexternal surface of the wall of the hose formed from the helical windingof the extruded web to provide the wall a support helix thatincorporates the first heating wire and the second heating wire;exerting tension on the first heating wire as the first heating wire isfed into the second extruder, and as the extruded bead is wound onto andabout the external surface of the wall of the hose, to draw down thefirst heating wire toward the central axis of the hose such that thefirst heating wire migrates radially inward within the extruded beadfrom the first location already within the cross-section of the extrudedbead to a second location within that is still the cross-section of theextruded bead, and that is closer to the wall of the hose and closer tothe central axis than the first location within the cross-section of thefirst extruded bead; and exerting tension on the second heating wire asthe second heating wire is fed into the second extruder and as theextruded bead is wound onto and about the external surface of the wallof the hose to draw down the second heating wire toward the central axisof the hose such that the second heating wire migrates radially inwardwithin the extruded bead from the third location already within thecross-section of the extruded bead to a fourth location that is stillwithin the cross-section of the extruded bead, and that is closer to thewall of the hose and closer to the central axis than the third locationwithin the cross-section of the first extruded bead.
 13. The method ofclaim 12, wherein: the cross-section of the extruded web includes a pairof guide formations that extend radially outward from the wall of thehose after the extruded web is helically wound about the mandrel or theat least one rotating rod; and the method further comprises using thepair of guide formations to guide the placement of the first extrudedbead on the wall as the first extruded bead is helically wound about thewall.
 14. The method of claim 12, further comprising helically windingthe extruded bead about the wall of the hose to provide a predeterminedamount of space between adjacent coils of the first support helix toallow a fold, a curve or a convolution to be formed in stretches of thewall between the adjacent coils of the support helix to enable the hoseto bend or to be axially compressed along the central axis.
 15. Themethod of claim 12, wherein the hose making apparatus comprises: a firsttensioner incorporated into a first spool of the first heating wire orinterposed between the first spool and the second extruder to performthe exertion of tension on the first heating wire; and a secondtensioner incorporated into a second spool of the second heating wire orinterposed between the second spool and the second extruder to performthe exertion of tension on the second heating wire.
 16. The method ofclaim 15, further comprising adjusting the tension exerted on at leastone of the first heating wire and the second heating wire as the hose isformed to vary at least one of the second location of the first heatingwire radially relative to the central axis within the support helix andthe fourth location of the second heating wire radially relative to thecentral axis within the support helix.
 17. The method of claim 12,wherein: when the extruded bead is helically wound onto and about theexternal surface of the wall of the hose, the extruded bead is in amolten state that enables the first heating wire and the second heatingwire to migrate within the extruded bead, and the wall of the hose isnot in a molten state that would enable the first heating wire and thesecond heating wire to migrate through the external surface of the wallof the hose such that the external surface of the wall is able to stopthe radially inward migration of the first heating wire and the secondheating wire within the extruded bead at the external surface of thewall; and the method comprises: exerting the tension on at least one ofthe first heating wire and the second heating wire to cause radiallyinward migration of the at least one of the first heating wire and thesecond heating wire fully through the plastics material of the extrudedbead and onto the external surface of the wall; and relying on theexternal surface of the wall being not in a molten state to stop theradially inward migration of the at least one of the first heating wireand the second heating wire.
 18. The method of claim 12, wherein: thefirst heating wire comprises a first conductor sheathed by a firstinsulator; and the second heating wire comprises a second conductorsheathed by a second insulator.
 19. The method of claim 18, comprisingconnecting the first conductor directly to the second conductor at oneend of the hose to form an electric loop by which the first heating wireand the second heating may be caused to cooperate to heat an interior ofthe hose by the provision of electric power to the first heating wireand the second heating wire at an opposite end of the hose.
 20. Themethod of claim 12, further comprising; cutting the hose into multiplesegments of the hose wherein each segment of the hose is cut to a lengthselected to be longer than needed to provide an extra length of the hosewithin each segment; unwinding a portion of the support helix from theextra length of the hose within each segment; heating the unwoundportion of each segment to straighten the unwound portion; strippingpart of an end of the unwound portion of each segment to expose thefirst heating wire and the second heating wire; and directly connectingthe first heating wire of each segment to a first electrical contact ofan electrical connector and directly connecting the second heating wireof each segment to a second electrical contact of the electricalconnector to enable the first heating wire and the second heating wireto be operated to heat an interior of the segment of the hose.